Toner cartridge, contact device and method for developer roller and toner cartridge used therein

ABSTRACT

An image forming apparatus or toner cartridge component thereof uses a bias voltage contact device that fits into an electrobushing which transmits the electrical contact has been invented. Thus, now a bushing can also act as an electrical contact and thereby a spring is not a requirement. The cylindrical bias voltage contact fits into a developer roller and has a smaller portion that is also cylindrical and fits into an electrobushing. The electrobushing is contacted electrically to the power supply of the image forming apparatus. The cylindrical bias voltage contact may have a cylindrical portion that fits into the developer roller by press fit with the new feature where the cylindrical portion has more than one diameter for obtaining a better press fit.

This Application is a Continuation of Ser. No. 09/996,453 filed on Jul.10, 2000, now U.S. Pat. No. 6,606,467, which is a Continuation-In-Partof Ser. No. 09/613,145 filed on Jul. 10, 2000, now U.S. Pat. No.6,321,048, which issued on Nov. 20, 2001, which is aContinuation-In-Part of Ser. No. 09/109,309 filed on Jun. 30, 1998, nowU.S. Pat. No. 6,131,261, which issued on Oct. 17, 2000.

BACKGROUND OF THE INVENTION

In the parent Application, claims were obtained on the arbor press withextender, including methods. The second Application focused on theimproved toner cartridge, contact device, image forming apparatus andmethods also described in the Application. This Application will alsofocus on the improved toner cartridge, contact device, image formingapparatus and methods also described in the Application. The reason alldevices and methods were entered in the same Application is becauseoriginally the Arbor Press, Extender and Methods were invented for thepurpose of press-fitting the contact device of this invention. However,it was found that this Arbor Press, extender and methods were a pioneerpatent in many industries without limit and inventor did not want tolimit it to the imaging industry as it has utility in so manyindustries. This continuation-in-part, however, concerns the improvedtoner cartridge, image forming apparatus, contact device and methodsthereof.

This invention relates to solving problems in Xerography and morespecifically in the toner cartridge remanufacturing industry. Thisincludes copiers, laser printers and facsimile machines which will bereferred to as imaging machines. This invention also relates to theindustrial machinery industry.

CANON has designed an all-in-one cartridge as seen in U.S. Pat. No.4,975,744, issued Dec. 4, 1990 and assigned to CANON. Several companieshave used these cartridges in laser printers, copy machines andfacsimile machines, each with the varying printer engines and adifferent nameplate. Originally, these cartridges were designed to be“disposable”. However, after the first all-in-one toner cartridge wasintroduced, it did not take long before laser cartridge remanufacturerssuch as myself began remanufacturing these cartridges. These“disposable” cartridges were designed to function for only one cartridgecycle without remanufacturing. The remanufacturers had found certaincomponents that needed replacement on a regular basis. In 1990, thefirst aftermarket photoreceptor drum became available for use inremanufacturing the all-in-one cartridge of the “SX” engine variety, themost popular printer cartridge from around 1987 through 1993. When thelong-life photoreceptor drum became available, the entireremanufacturing industry turned around and gained great strength andbegan a huge growth surge that still continues. In October 1993,HEWLETT-PACKARD, the largest seller of this printer engine using theall-in-one cartridge, entered the cartridge remanufacturing industrywith the “Optiva” cartridge, further increasing the size as well ascredibility of this relatively new industry. However, this relativelynew industry grew from the all-in-one cartridge shortly after its debut.Before the introduction of the long-life drum, sometimes called the“superdrum” or “duradrum”, the SX cartridge would last for around threecartridge remanufacturing cycles at best, since the actual useful lifeof the OEM drum was three cycles. However, the long-life drums got theirnames from the fact that they were designed to last for manyremanufacturing cycles or recharges as they are sometimes called.Typically, the long life drum can last for ten or more such cycles,unlike the typical OEM (Original Equipment Manufacturer) drum. With theadditional developments of drum coatings, originally designed for OEMdrums, the long-life drum may last for many additional cycles. Somecoatings, in theory, were designed to be dissolved and removed from overthe drum surface every 1-3 cycles, so the drum life of the long-lifedrum almost seems limitless.

However, with photoreceptor drums lasting for many cycles, othercomponents of the cartridge have a tendency to require greaterdurability, a better solution, or a greater life. Also, as the successof these cartridges has skyrocketed, the demand is for cartridges withlonger cycles, so component improvements are significant. Therefore,avoiding natural problems with prevention means must also be implementedfor cartridges of longer life both in longer cycle times and greaternumber of cycles. One good example is the electrical contact used inmany developer rollers of toner cartridge assemblies.

Inventor was awarded U.S. Pat. Nos. 5,634,175 and 5,648,838 forelectrical contacts for developer roller assemblies. To properly installan electrical contact from the above patents in, the most robust way,one would want to press-fit the contact into the inner wall of thedeveloper roller. It sounds simple. However, you can not just get anarbor press and press fit the contacts because arbor presses have a veryshort maximum press-fit height. Most arbor presses look alike, just thatsome are bigger and more powerful than the others, among the most commonarbor presses. However, a ½ ton arbor press has a 4 inch height and aone ton press is not much higher, a two ton press is not much higher andeven a 5 ton arbor press typically is not very high. To press-fitcontacts into developer rollers, most developer rollers are over teninches long and even an expensive 5 ton arbor press, much greater inweight and power than necessary, is not long enough to press-fit allsizes of developer rollers. In another example, the WX (5Si) developerroller is over 18 inches long and would not even fit in a 5 ton arborpress in the typical case. To solve this problem, inventor has developedan arbor press extender device to lengthen the maximum press length thatan arbor press may press. Thus, with this invention, even a small ½ tonarbor press may be used for press-fitting an electrical contact on along developer roller sleeve. With the extender device of thisinvention, there is no limit in the maximum allowable press length thatmay be pressed with an arbor press, and thus, a small ½ ton arbor presswith the extender device of this invention may press a part of a greaterlength than a large 5 ton arbor press without the extender device ofthis invention which saves a lot of money.

An electrobushing will be introduced that is a bushing for truingrotational motion of a developer roller while at the same time acting asan electrically contacting device. This simplifies number of parts andmakes a stronger connection and thus may obsolete the use of spring withcontact.

SUMMARY OF THE INVENTION

Accordingly, it is object of this invention to show an improved contactreceiving device that not only improves rotational trueness of developerrollers, but also is a link in the electrical contact's connection, thusmaking improved toner cartridges and improved image forming apparatuses.

It is yet a further object of this invention to show an improved contactreceiving device to improve rotational trueness of developer rollers.

It is an further object of this invention to show an arbor pressextender device to increase the length that a press-fit may beperformed.

It is a further object of this invention to show an arbor press extenderwith modular fixtures and fixture holders that receive each end of thedeveloper roller including an electrical contact that may be press-fit.

It is still a further object of this invention to show an arbor pressextender with fixtures that receive each end of the developer rollerincluding an electrical contact that may be press-fit.

It is yet a further object of this invention to show modular fixtures tofit into fixture holders to allow quick change from one type ofpress-fit to be performed to another with minimal set-up time betweenpress-fit styles and sizes.

It is yet a further object of this invention to show quicksnap-on/snap-off fixtures and fixture holders for quick connect/quickdisconnect of fixtures to fixture holders where fixtures may be heldfirmly in place without falling off the fixture holder using the conceptused in quick connect air hose connections.

It is yet a further object of this invention to show modular fixtureholders and fixtures for press fitting applications that quickly installand uninstall using air-hose quick-connect couplers and nipples.

It is yet a further object of this invention to show modular fixtureholders and fixtures for press fitting applications that quickly installand uninstall using a small piece of hose in the bore of the fixturemodule to make a tight yet removable quick connection.

In carrying out this invention in the illustrative embodiment thereof,an arbor press is equipped with an extender device to increase themaximum allowable part length that may be pressed. This not onlyeliminates the need for using a larger press by allowing a smaller pressto be used for pressing long parts, which also saves money, but someparts which may be too long to fit on a much larger arbor press may nowbe pressed on a small arbor press. Modularquick-connect/quick-disconnect fixtures may be used to fit in fixtureholders for holding firm different types of parts and different stylesof developer rollers which may now be press-fit using this extenderdevice of this invention. With this extender device, even extremely longparts may be press-fit economically which opens new doors forapplications using arbor presses in many industries as a result of thisinvention. Even an adjustable length arbor press extender may be usedfor variable extender length for multiple applications with one extenderdevice. An electrobushing is a bushing that conducts electricity to adeveloper roller in a toner cartridge which is a component of an imageforming apparatus or directly in an image forming apparatus for improvedtoner efficiency, darker print, more even print and an improved system.

BRIEF DESCRIPTION OF THE DRAWINGS

This invention, together with other objects, features, aspects, andadvantages thereof, will be more clearly understood from the followingdescription, considered in conjunction with the accompanying drawings.

FIG. 1 is an isometric view of a prior art toner hopper assembly showingthe breakdown of the developer roller and OEM electrical contacts andend fittings.

FIG. 2 is an isometric view of a prior art toner hopper assembly showingthe breakdown of the developer roller and some aftermarket electricalcontacts and end fittings.

FIG. 3 is an isometric view of a prior art toner hopper assembly showingthe breakdown of the developer roller and some aftermarket electricalcontacts.

FIG. 4 is an isometric view of an end portion of a prior art tonerhopper assembly showing the breakdown of the contact end of thedeveloper roller, some aftermarket electrical contacts and the printercontact.

FIG. 5 is an isometric view of an aftermarket electrical contact.

FIG. 6 shows an isometric view of a prior art developer roller sleeve,showing the shaft and inside the contact end of the developer roller.

FIG. 7 is an isometric view of an aftermarket bushing used to receivethe electrical contact which functions with the electrical contact tomake electrical connection.

FIG. 8 shows an isometric view of a metal bushing for receiving the endof a developer roller that prevents wobble, trues rotation and mayoptionally act as a link in the electrical contact's connection, shownprior to the press-fit of the aftermarket electrical contact.

FIG. 9 shows an isometric view of a prior art developer roller sleeveend, showing the shaft, new and improved electrical contact and metalbushing after the electrical contact is press-fit in place.

FIG. 10 shows an isometric view of a prior art developer roller sleeveend, showing the shaft, new and improved electrical contact and metalbushing after the electrical contact is press-fit in place and metalbushing is in proper position.

FIG. 11 shows an isometric view of a typical prior art arbor press thatcan be found at most tool supply distributors.

FIG. 12 shows an isometric view of an arbor press with the new extenderadded to the arbor press also showing the upper fixture holder module.

FIG. 13 shows an isometric view of an arbor press with the new extenderadded to the arbor press, also showing the top and bottom fixture holdermodules.

FIG. 14 shows an isometric view of an arbor press with the new extenderadded to the arbor press, also showing the top and bottom fixture holdermodules with a developer and aftermarket contact in place.

FIG. 15 is an isometric view of a new and improved aftermarketelectrical contact.

FIG. 16 is an isometric view of an upper fixture holder.

FIG. 17 is a cutaway view of an upper fixture holder.

FIG. 18 is an isometric view of an lower fixture holder.

FIG. 19 is a cutaway view of an lower fixture holder.

FIG. 20 is an isometric view of an upper fixture holder with a fixturemodule attached.

FIG. 21 is a cutaway view of an upper fixture holder with a fixturemodule attached.

FIG. 22 is an isometric view of an lower fixture holder with a fixturemodule attached.

FIG. 23 is a cutaway view of an lower fixture holder with a fixturemodule attached.

FIG. 24 is an isometric view of an upper fixture holder with a malefixture module attached.

FIG. 25 is an isometric view of a male fixture module.

FIG. 26 shows a cutaway isometric view of an arbor press with foam inthe arbor press opening to prevent the magnetic developer roller fromgetting damaged.

FIG. 27 shows a cutaway top view of an arbor press with foam in thearbor press opening to prevent the magnetic developer roller fromgetting damaged.

FIG. 28 shows an isometric view of an arbor press with foam in the arborpress opening to prevent the magnetic developer roller from gettingdamaged.

FIG. 29 shows a prior art universal quick connect coupler for making anair hose connection that is capable of receiving the three quick connectdifferent style nipples in the figure.

FIG. 30 is a prior art quick connect coupler with male pipe threads atthe permanent/semi-permanent connection end.

FIG. 31 shows a prior art quick connect nipple with male pipe threads atthe permanent/sem-permanent connection end.

FIG. 32 shows a quick connect upper fixture holder using a coupler forquick connect features.

FIG. 33 shows a cutaway isometric view of a typical prior art quickconnect coupling and nipple used for connection of air hoses.

FIG. 34 shows a cutaway isometric view of a typical prior art quickconnect coupling and nipple used for connection of hydraulic lines.

FIG. 35 is a digital image showing a cutaway of a typical hose material.

FIG. 36 shows a small piece of hose used to fit in the bore of a modularfixture holder for quick installation and removal of removable fixtures.

FIG. 37 shows the outside view of an endcap assembly of a developerroller assembly showing the printer contact.

FIG. 38 shows the inside view of an endcap assembly of a developerroller assembly showing the printer contact attached to the ringcontact.

FIG. 39 is an isometric view of a typical toner cartridge.

FIG. 40 is an isometric view of a waste toner hopper.

FIG. 41 is an isometric view of a toner hopper.

FIG. 42 is an isometric breakdown of a toner hopper and its components.

FIG. 43 breaks down more components of a toner hopper so that you maysee the components that were covered up inside the toner hopper.

FIG. 44 shows an isometric cutaway view of a waste toner hopper.

FIG. 45 shows a typical image forming apparatus.

FIG. 46 shows an end-view cutaway of a typical waste toner hopper.

FIG. 47 shows a cutaway enlargement of a photoreceptor and a developerroller and shows the charging in the typical case and is not to scale.

COMPLETE DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 45 shows a typical image forming apparatus 350 which may be eithera printer, a copy machine or a facsimile machine. Some image formingapparatuses use a toner cartridge 351 shown in FIG. 39 while others haveall components built into the image forming apparatus 351. The tonercartridge 351 is typically made up of two components, the toner hopper352 and the waste toner hopper 353. FIGS. 40-41 show another set oftoner hopper 362 and waste toner hopper 363. The toner hopper has adeveloper roller 364 and a contact 365 and a tank 366. The waste tonerhopper 363 has a photoreceptor 367, a charge roller 369 and a waste tank368. FIG. 47 shows a theoretical developer roller 307 showing the magnetcore 310 inside the developer roller 307.

The toner is attracted from the developer roller 307 to thephotoreceptor drum 308 as illustrated in FIG. 47. The toner 309 iscomposed of black plastic resin bound to iron particles. The developerroller 307 has a magnetic core 310 so the toner particles are attractedto it. As the roller 307 rotates with toner 309 on it, the doctor blade306 controls the thickness of toner on the surface of the developerroller 307. Newer devices use a urethane spreader blade 320 held inplace by being on a metal assembly 321 as shown in FIG. 43. The plastictoner particles receive a negative surface charge by rubbing against thedeveloper roller because the roller 307 is connected to a DC supply. Theelectrostatic charge on the particles attracts the toner 309 particlesto uncharged portions of the photoreceptor drum 308 that have removedcharge from pixels of light. The charged areas of the photoreceptor drumrepel the toner particles. An AC potential on the developer roller 307helps move the toner 309 to the photoreceptor drum 308 at the desireduncharged areas yet helps toner come back to the developer roller 307from charged areas of the drum 308 to improve density and contrastbecause the AC charge alternates.

The roller 307 has a non-print region 322 and 323 shown in FIG. 43. Inthis nonprint region 322 and 323, the developer roller 307 is smootherthan the toner transport section 312 of the roller 307. Toner is notallowed to adhere to the surface of the roller 307 in the nonprintregion 322 and 323. Typically, a felt pad 324 forms a semicircle,partially around the roller 307 and seals off the end of the roller 307to prevent toner leakage from the assembly 305. The smooth felt pad 324keeps the nonprint region 322 of the roller 307 clean or free of tonerand other debris. Also, in some models, a plastic member (not shown)attached to the doctor blade 306 has an extension (not shown) whichscrapes toner from the area of the non-print region 322 and 323 of theroller 307.

In older toner cartridge assemblies like SX, the all-metal doctor bladeis charged the same as the developer roller bias, and is on the samecircuit, and similarly the frame of the NX doctor blade is charged.

It should be noted that the toner transport section 312 of the developerroller 307 cannot be an electrical contact point for two reasons. First,it has a rough surface, typically etched and sandblasted with glassbeads or other special treatment such as a conductive coating. Secondly,the section 312 has a continual layer of toner on it. This toner isready to be transported to the photoreceptor drum.

FIGS. 44 and 46 show another waste toner hopper 401. The waste tonerhopper has a wiper blade 402 or cleaning blade 402 with a sharp cuttingedge 403. The waste toner hopper has a tank 404. There is a recoveryblade 405, sealing blade 405 or keeper blade 405 that acts as a seal sothat as waste toner is scraped into the waste tank 404, the toner willfall through the opening 406 between the cleaning blade 402 and therecovery blade 405. The recovery blade 405 has a pickup magnet 407nearby to pick up any toner that may leak out when the enduser removesthe toner cartridge 351 from the image forming apparatus 350 for anyreason.

FIG. 1 is a broad illustration of the EX toner hopper 10 used in the HPLASERJET series 4 printer. The developer roller 2 has an end 3 fromwhich the magnetic core 4 and magnetic core shaft 1 extend and thedeveloper roller has another end 7. At the opposite end of the developerroller 2 from the magnetic core shaft 1 is the magnetic core shaft 6 andwhich is smaller than the magnetic core 5 in diameter. The prior artinsulative-plastic developer roller contact device 8 fits into the end 3of the developer roller 2. The magnetic core shaft 1 and 6 are unitarywith the magnetic core 5. A white plastic insulative bushing 9 fits overthe end 3 of the roller 2 and the contact device 8. An alignment piece12 (shown in FIG. 2) with an opening aligns the entire connectionrelative to the metal contact plate 14 mounted on the end-cap 14 a ofthe toner hopper assembly 10 The metal contact plate 14 connects thecontact device 8 with a printer contact 13, which in turn connects withthe printer's electronic circuitry. The contact device 8 has a wire. Atone end the wire 182 touches and makes contact with the contact plate14. At the other end the wire 183 touches and makes electrical contactwith the inner wall of the developer roller 2.

This is a very poor bias voltage contact system. As a result of the poorcontact, the printed image lacks quality after the spring wire 182 and183 loses its resiliency, either where the spring wire 182 and 183touches the contact plate 14 or where the spring wire 183 contacts theinner wall of the developer roller sleeve 2.

The spring wire is continuous from 182 where it rotates on the contact 8and at the same time contacts the contact plate 14 to 183 where itcontacts the inner wall of the developer roller sleeve 2. Alternately,the spring wire 182, 183 may get insulated either by toner or oxidationfrom aging, environment and extreme use. The more the contact device 8is used, the worse the image gets. Another contributing factor is theaged and used surface of the developer roller 2. However, the wire 182,183 deteriorates and gradually the image degrades in steps, however,when this process is combined with the conditions of the developerroller's 2 surface, it is a defective like a shotgun shooting out of twobarrels at the same time with multiplying effects. However, the contactfrom the wire 182 to the metal contact plate 14 is poor in the firstplace because wire is thin and also there is not a lot of spring wiresurface area to contact. There is just a small point to make contactwith the ring of the end-cap assembly (FIG. 38) and a small point 183 tocontact the inner wall of the developer roller 2. Consequently, it is anaccident waiting to happen. As the spring wire 182 and 183 losesresiliency in time, it loses its contact effectiveness. The same is truewhere the spring wire 183 contacts the inner wall of the developerroller 2. As time passes and more print cycles are completed, the springwire 182, 183 loses its resiliency and the integrity of the contact ofthe spring wire 182, 183 to the inner wall of the developer roller 2 isdetrimentally affected to the point where the print quality of the imagedegrades.

The contact device 8, and thus the spring wire 182 and 183 rotate withthe developer roller 2. The spring wire 182 moves relative to the metalcontact plate 14. The mechanical motion makes the spring wire 182 evenmore susceptible to loss of resiliency, oxidation, dust, toner and wear.

These problems led to the development of the devices shown in U.S. Pat.No. 5,634,175, and improvement of the contact device for use in the EXtoner hopper assembly 10. FIGS. 2 and 3 show the contact device 15, thefirst aftermarket device for the EX toner hopper. The contact device 15comprises a metal bushing with a large diameter portion 19 sized to fitinto the end 3 of the developer roller 2 where the large diameterportion 19 of the contact device 15 is completely inserted into thedeveloper roller 2, providing additional electrical surface area betweenthe contact device 15 and the roller 2.

FIG. 2 is a broad illustration of how the developer roller contactdevice 15 is connected with the toner hopper assembly 10. In oneoptimized design, the large diameter portion 19 is inserted into the end3 of the roller 2, and the plastic bushing 9 is slipped over the rollerend 3 and contact device 15. The small diameter portion 18 is thenpressed against the coil spring 11 and into the opening 16 in theinsulative alignment piece 20, and the developer roller 2 is mounted onthe toner hopper assembly 10. The contact device optionally may have arim 17. FIG. 3 is an enlarged view of the relevant end of the tonerhopper assembly 10 to more clearly illustrate the contact device 15connection. The alignment piece 20 and coil spring 11 are shownseparated from the assembly 10 for clarity. The outer surface of thelarge diameter portion 19 of the contact device 15 may be adhered byglue or conductive glue to the inner wall of the developer roller 2.However, for best results, a press fit would make the best electricalcontact, much better than gluing the contact. Also by press-fitting thecontact 15, the contact, which in this case also acts as an alignmentshaft, will have a more true rotational motion. The developer roller hasa nonprint region 23 on one end and there is also a nonprint region onthe other end. The magnet core reduces in diameter first at referencenumber 22 and then it reduces further to form a magnet core shaft 21.

FIGS. 4 and 5 show another contact device 25 from inventor's U.S. Pat.No. 5,634,175 used in the LX toner cartridge. The contact device 25comprises a cylindrical member 26 with a rim 27. The cylindrical member26 has an outside diameter sized to snugly fit inside the end 31 of thedeveloper roller 24. The rim 27 is sized to abut against the end 31 ofthe developer roller when the cylindrical member 26 is completelyinserted within the developer roller 24. The interior of the contactdevice 25 has two portions. The first portion 28, adjacent the rim endof the contact device 25, has an inside diameter sized to slide over thewasher 33 in the printer electrical contact 36. The second portion 29has an inside diameter sized to fit around the end of the magneticcore's shaft 4 within the developer roller 24. A contact surface 30 isformed where the interior portions 28 and 29 meet in a linear direction.The contact surface 30 remains in contact with and rubs against the faceof the washer 33 which is unitary with the projection 35 which connectswith the printer's electronic circuitry within the printer electricalcontact 36 when the developer roller contact device 25 rotates with thedeveloper roller 24. This specific printer electrical contact 36 alsohas an insulative plastic cap 32 and an insulative plastic assembly 34within the printer contact device 36.

It has been found that the developer roller contact device 25 workswell, fitting by snugness without adhesive. However, it has been testedusing adhesive to adhere the contact device 25 within the end 31 of thedeveloper roller 24 and there was no ill effect. When using adhesive,one must be careful not to create an insulative layer that would preventcontact. The only purpose of glue is to prevent the contact device 25from spinning within the developer roller sleeve 24 which would machinea groove within the roller. Conductive adhesives may be used. However,it has been found that using a press-fit contact 25 eliminates the needfor glue, improves the contact and makes for a more true rotation of thedeveloper roller sleeve 24. With the developer roller contact device 25,electrical contact with the developer roller 24 is maintained not onlywhere the rim 27 abuts against the end 31 of the roller 24, but alsowhere the cylindrical member 26 touches the inner wall of the roller 24.

For any such contacts, a very small amount of conductive grease shouldbe applied wherever rotating parts make electrical contact withstationary parts and vice versa. There are two basic types of conductivegreases in the aftermarket, white grease and black grease. Black greasemeasures conductivity with an ohmeter and white grease does not.However, white grease nonetheless performs as well even though it doesnot measure actual conductivity and solves the problems that conductivegrease is there to solve, i.e., stability of contact, prevention ofcontact-loss, arc prevention and corrosion resistance. Inventorintroduced the first aftermarket conductive grease to the tonercartridge remanufacturing industry in an article he wrote that waspublished in Recharger in 1992. Black grease has the major disadvantagethat by the end of a cartridge remanufacture cycle, the black greaseforms a hard layer on the outer surface and thus requires cleaningbetween every recharge cycle. However, hardened black grease does remainconductive when transformed to the hardened solid state. It is becauseof the cleaning requirement of the black grease that is a costlynuisance that has convinced inventor that the black grease is notrecommended and that the white grease is. By the end of a tonercartridge cycle, the white grease is partially gone, thus sacrificiallydoing its job, but does not require any cleanup of components like blackgrease does.

It has been found that the best manufacture of such electrical contacts15 and 25 may be made using a press-fit rather than requiring the use ofa glue. Thus the tolerances must be plus and minus 0.005 inches in thetypical case in dimensions that involve press fit for the EX developerroller 2. This is the tolerance available in manufacture without takingspecial precautions that would otherwise increase the manufacture costsof the contacts 15 and 25.

FIG. 6 shows a developer roller 37 of the HP-4000 toner cartridge. Theroller has a left side 38, a right side 39, a metal shaft 41, a rightside bushing 44, a right side 45 of metal shaft 41, a left and right end43 and 46 of metal shaft 41 and an inner bore 42. It can be seen in thefigure that just to the right of the inner bore 42, the bore dimensionof the developer roller sleeve 37 is smaller in diameter. Thus, theinner bore 42 is a counter bore in the smaller bore to the right. It isin this inner bore 42 where the plastic OEM contact fits in the HP-4000developer roller 37 (not shown). This OEM contact is essentially thesame as the EX contact 8 shown in FIG. 1. The OEM contact 8 rotates in aplastic wearable modular receiving bore assembly not shown. The problemis that the modular receiving bore assembly made of plastic can enlargein bore size and thus cause the developer roller 37 to have a slightwobble. This slight wobble would cause the developer roller to havechatter and appear worn prematurely. In other cases, the out-of-roundmodular receiving bore assembly can cause the developer roller tophysically contact the metal of the magnetic end-seal (not shown) thatreplaces the end-felts of old. When the developer roller touches themagnetic end-seal, you can kiss the developer roller sleeve 37 goodbyebecause the metal along the side of the end-seal will machine a grooveinto the soft aluminum developer roller sleeve 37. This is almost thesame as putting the developer roller sleeve 37 on a lathe and having ametal tool cut into the aluminum tube 37.

FIG. 7 shows the electrobushing 47 that is designed to replace theremovable all-plastic OEM receiving bore assembly. It looks similar inshape, but the electrobushing is metal or conductive plastic and themodular receiving bore assembly has different shapes on the outside forfitting into the end-cap assembly 173 (FIGS. 37 and 38) with a groove tolock into the end-cap assembly 173. The electrobushing 47 was made in asimpler way to decrease manufacturing costs and thus roundness is thekey. However, the electrobushing was made to make contact with the leftend 53 to the printer contact 173 and thus was designed a little longerin length than the OEM plastic bushing. By being a little longer theelectrobushing 47 will make tighter fit of the developer roller 37 inthe toner hopper, but will maintain electrical contact by being tighter.The electrobushing 47 has a rim 49, a left surface of rim 48, or a flatring shaped portion 48, a bore 50, a cylindrical portion 51, a circleportion 52 where the cylindrical portion 51 joins the rim left surface48. The end-cap 173 has two holes 178, to hold it in place, a metal flatspring contact 176 which connects to a contact ring 177, all in onemetal piece. The left end 53 of the electrobushing 47 is longer than theOEM's plastic bushing design so that, unlike the OEM bushing, theelectrobushing left side 53 makes contact with the metal contact ring177 for better electrical contact. The OEM plastic bushing fits insidethe plastic sleeve receiving wall 181 as does the electrobushing 47. Theprinter electrical contact assembly 173 has an outer surface 174 and aninner surface 175 and each plastic insulative surfaces.

FIG. 8 shows an exploded view of the electrobushing 47, the new contact54 and the developer roller 66. The electrobushing 47 is designed notonly to prevent the out-of-roundness of the OEM plastic bushing that cancause problems after the inner bore enlarges, but also helps thefunctioning of the contact 15. However, the contact bias voltage contact15 has been slightly improved by the bias voltage contact 54 of, whichis designed more optimally for a press-fit. Both contacts 15 and 54 areidentical except for the two steps 55 and 57 shown on the bias voltagecontact 54. The contact 54 has a smaller portion 55 (the first step) onthe press-fit side, a right end 56, a larger portion 57 (the secondstep) of the press-fit cylindrical portion, a joining portion 58 wherethe larger portion 57 joins the smaller portion 55, a rim 59, a secondjoining portion 60 where the rim 59 joins the larger portion 57, s flat61 surface of rim 59, an alignment portion 62, a bore 63 in thealignment portion, and an end surface 64 in the alignment portion 62.The press-fit contact 54 has a second bore (not shown) through thesmaller portion 55 and the larger portion 57 that is larger than thediameter of the magnetic core (not shown) on the shaft 41. The press-fitcontact 54 is to be press-fit onto the developer roller sleeve 66 whichhas an inner bore 42, a left rim 68, and a counter bore portion 69 ofthe inner bore 42. A counterbore may be made in the developer rollersleeve 66 which results in an outer bore portion 69 and an inner boreportion begins at 42 where the inner bore diameter in this example isidentical to the original diameter of the developer roller sleeve priorto putting the counterbore in it. It is clearly seen in FIG. 8 that thelarger portion 57 of the bias voltage contact 54 fits in the outer boreportion 69 and the smaller portion 55 of the bias voltage contact 54fits in the inner bore past reference 42 where the diameter is smaller.The fit may be any kind of fit desirable for the application whichincludes a loose-fit, free-fit, medium fit, snug-fit, wringing-fit,tight-fit, medium-force-fit, heavy-force-fit, shrink-fit, press-fit,interference fit, or any kind of fit whatsoever without limit. There isnot limit in what tightness may be used to fit the bias voltage contactdevice 54 or any other bias voltage contact device in this patentapplication into the developer roller.

Please note that for any bias contact device 54, it may also be called acylindrical member, flange, double-cylindrical member or any namewhatsoever. Note that with the multi-diameter contact 54, a press-fit orother fit may be achieved in two diameter portions which add structuralrigidity, more true roundness, a more true fit, a more true rounddeveloper roller cylinder, better electrical contact, more stablerotation, increased surface-to-surface touching for a better electricalcontact for a more stable rotation. Note that the contact device 54 maybe implemented either on the drive side or on the non-drive side of thedeveloper roller. With the two-diameter step, a greater fit may beachieved with or without the press-fit as even a loose fit may beimplemented, although there is no limitation. Of course, if it is usedon the drive side, a gear would probably be placed on the small diameterportion, depending on the operating requirements of the environment.

FIG. 9 is an exploded view of the electrobushing 47 with respect to thedeveloper roller sleeve 66 with the contact 54 already press-fit intothe developer roller 66. FIG. 10 shows the same as FIG. 9 witheverything in place including the electrobushing 47. The press-fit ofthe contact 54 may be done with a hammer. However, by hammering thecontact 54 into the inner bore 42 of the developer roller sleeve 66 maycause problems. For example, the contact, made of steel, brass or bronzecan cause score and scratch marks into the inner bore 42 of thedeveloper roller sleeve 66 and can cause out-of-roundness of thedeveloper roller sleeve 66. Thus, it is a good idea to press-fit theparts with a press instead of a hammer. The least costly and commonpresses used for press-fits are arbor presses. They are used bymechanics in garages to press-fit bearings and other mechanical fittingsthat require a press-fit. With an arbor press, a tremendous amount ofpressure may be exerted with a very small exertion on the part of theoperator by using leverage and a gear. Although much larger arborpresses exist, the most commonly available arbor presses range from onehalf to five ton pressure rating. Most any tool supply house for themachining industry, tool industry and automotive industry sells arborpresses. Arbor presses are readily available most anywhere in the USAand are relatively inexpensive. Most importantly, arbor presses are moresafe than power driven presses because the operator uses his or her handto increase or decrease the pressure.

FIG. 11 shows a typical arbor press 70. A typical arbor press 70 has ahandle 71 for manually exerting leverage pressure, and the handle has arubber end 72 at each end. The arbor press 70 has a straight ramassembly 73 with gear teeth 74, a straight non-gear portion 75, a ram76, and a top non-geared portion 82. The typical arbor press containsthe straight ram assembly 73, a cap 77, handle 71, a neck 78, a base 79with a base opening 80, a tightening bolt 81 to attach to the benchwhich goes through a bore (not shown) in the base 79. Prior art FIG. 11shows that the ram guide 200 is attached to the neck 78 of the arborpress 70. The cap 77 is secured to the ram guide 200 using four holdingbolts 204 tightening the face 201 of the cap 77. The cap 77 secures theram 73 in the ram guide 200. The tightness of the ram 73 inside the ramguide 200 is controlled by the tightness setting of the cap positioningbolt 203 which may be locked in position with the cap position lock nut202. The base or support structure 79 has a top 205, a bottom orunderside 206, a right side 207 and a left side 208.

All structural portions are thick, especially the base 79 and the neck78. There is one major flaw in these popular arbor press devices 70. Thefirst flaw is that they are heavy. A ½ ton arbor press weighs over eightpounds. The second flaw is that arbor presses are designed for smallparts. If the automotive industry uses the arbor press for press-fittingbearings, then they don't have to be capable of press-fitting longparts. The typical arbor press 70 limits in press-fit length are fromthe bottom of the cap 77 to the top of the base 79. However, the maximumpart length is shorter yet because the figure does not show the metalpiece that comes with most arbor presses to cover up the base opening 80to enable press-fitting. By removing this metal cover of the baseopening, parts may extend down to the workbench to gain another 2-3inches in length of a part to be pressed with an arbor press 70. Theonly solution prior to this invention was to use a different kind of apress or use a larger arbor press. There is a large difference between a½ ton arbor press and a 5 ton arbor press in cost and weight. There isnot a large difference between a ½ ton arbor press and a 5 ton arborpress in length of a part to be pressed. Even so, why should a person ora company have to purchase an overpowered arbor press at great expenseto do a small job just because an arbor press is too short. It is simplybecause arbor presses, which are mass produced to keep costs down, arenot designed for applications outside the range of height simply becausemost users of arbor presses do not need to press a long part. Those thatneed to press a longer part are in the minority and must find analternative that is not an arbor press. Inventor did not find analternative, but instead made an extender device that attaches to anarbor press to increase the length of a part that may be pressed with anarbor press. However, the extender device 83 may also be installed inbrand new arbor presses, or even cast into the arbor press and is notlimited just what is described in this invention.

FIG. 12 shows an arbor press with an extender assembly 83 used toincrease the length of parts that may be pressed. The extender assembly83 has a right leg 84 and a left leg 85, optionally a fixture attachbore 87 which may optionally be threaded, a base 86, a left bend 91, aright bend 90, and two attach holes 88 and 89. Alternately, and extenderassembly may be made with multiple sets of attach holes 88 and 89 tomake an extender assembly 83 with multiple length settings. The holesmay be replaced with one or more slots that can be used to adjust theheight of the extender. Holes are drilled and tapped into the base 79 ofthe arbor press 70 at holes 88 and 89 to enable the bolting attachmentof the extender assembly 83 to the arbor press 70. There is an upperfixture holder module 92 on the ram 76 of the arbor press for attachingfixtures that position the parts to be pressed to insure that the pressfit will be straight and proper. FIG. 13 shows the same modified arborpress with a lower fixture holder module 94 for holding a variety offixtures for different applications, also to insure that the press fitwill be straight and proper, used in tandem with the upper fixtureholder module 92. Also shown in the figure is a inner surface 93 of thebase opening region 80.

FIG. 14 shows a laser printout of a digital image of the arbor press 70with the extender assembly 83, the upper and lower fixture holdermodules 92 and 94, a developer roller 2, and a press-fit contact 54being press-fit. FIG. 15 shows a laser printout of a digital image ofthe press-fit contact 54 that is used in FIG. 14 because this contact 54is difficult to see in FIG. 14. This figure shows that even though theupper fixture holder module 92 and the lower fixture holder module 94are meant to hold modular fixtures to firmly hold parts to be press-fitat top and bottom, the fixture holder modules 92 and 94 may also be usedas fixtures as in FIG. 14. By causing the fixture holder module to bebased on a widely used size, then all the fixture holders can fit intothat size to economize on the number of fixtures required to fit intothe fixture holders. Different embodiments of these fixtures will laterbe described.

The extender assembly 83 is actually very simple. Some of the bestpioneer inventions are simple. The extender assembly 83 is comprised offlat bar cold rolled steel flat bar ⅜ inches thick and 1 and ¾ inchwide. The extender 83 has two right angle bends at 90 and 91. Otherdimensions would also work. However, inventor will manufacture this withthe above dimensions for strength purposes but does not want to limitinvention to these dimensions. The extender assembly 83 should functionproperly with almost any dimensions as long as it increases the lengthof a part that an arbor press can press.

FIGS. 16 and 17 show the upper fixture holder module 92 which has asmall bore 95, a larger bore 96, a top 97, a bottom 98, a bore joiningdisk region 99, a top 100 of the smaller bore 95 and a bottom 101 of thelarger bore 96. This fixture holder may be bolted through the bores 95and 96 to the ram 76. It is easiest to use a bolt that may be tightenedwith an ALLEN wrench, the ALLEN wrench made to fit into the larger hole96 to allow turning the bolt. Optionally, the small bore 95 may betapped, however, it is easier to drill and tap a bore into the ram 76 toattach the upper fixture holder module 92.

FIGS. 18 and 19 show the lower fixture holder module 94 which has asmall bore 102, a larger bore 103, a top 104, a bottom 105, a borejoining disk region 106, a bottom 108 of the smaller bore 102 and a top107 of the larger bore 103 This fixture holder may be bolted from belowthe bottom 105 into the small bore 102, preferably threaded as shown inFIG. 19. The small bore 102 may be tapped to attach the lower fixtureholder module 94 to the base 86 of the extender assembly 83 on an arborpress 70.

FIGS. 20 and 21 show the upper fixture holder module 92 with an upperfixture 111 attached from the bottom 98 of the upper fixture holdermodule 92. A bolt 109 is shown to attach the upper fixture module 92 tothe ram 76. The fixture 111 has a bore 112 to receive the end of anyparts to be press-fit. The bore 112 has a bottom 113 where the press-fitpart may be inserted. When the press-fit part is steel or other materialthat is attracted by a magnet, the fixture 111 may be made magnetic sothe press-fit part can stay in by magnetism. One way to do this is tomake the fixture 111 of steel and to magnetize it although the same maybe done by using magnetite or magnetic steel. The fixture 111 has anupper fixture stem 114 and the stem 114 has a top 115. The fixture has abase 117 and a stem join base region 116, and a bottom 118 of the base117. It is not just that the bore 112 is designed to “fit parts” asearlier stated, but some parts to be pressed may have protrusions thatstick out and the bore 112 is designed to accommodate these protrusionsas well as make a nice fit.

FIG. 35 shows a typical rubber hose material 165. In this figure it hasthree layers 166, at the outer layer, 167 in the middle layer and 168 atthe inner layer. FIG. 36 shows a hose 169 cut to length and designed togo into the larger bore 96 of the upper fixture holder module 92. Withthis hose positioned tightly in the larger bore and optionally glued,upper fixtures 111 may be quickly slipped in the bore 172 of the hose169 by placing the stem 114 of the upper fixture 111 snugly in thehose's 169 bore 172 to fit snugly into the inner wall 179. The hose 169has a bottom 170, a top 171 and an outer surface 180. This upper fixture111 may be quickly installed and uninstalled when different fixtures 111which are used for press-fitting different parts are required.

FIGS. 22 and 23 show the lower fixture holder module 94 with a lowerfixture 119 attached to the top 104 of the lower fixture holder module94. A bolt 110 is shown to bolt the lower fixture module 94 to the base86 of the extender assembly 83. The fixture 119 has a bore 120 to fitthe end of any parts that stick out to be press-fit. The bore 120 has atop 121 where the press-fit part may be inserted. When the press-fitpart is steel or other material that is attracted by a magnet, thefixture 119 may be made magnetic. One way to do this is to make thefixture 119 of steel and to magnetize it although the same may be doneby using magnetite or magnetic steel. This might not be necessary sincegravity will hold the component in, but it is an option. The fixture 119has a lower fixture stem 122 that fits into the large bore 103 of thelower fixture holder module 94 and the stem 122 has a bottom 123 Thefixture has a top 126 and a stem join base region 124 and an outersurface 125.

The hose 169 may optionally fit in the larger bore 103 of the lowerfixture holder in order to have a quick install and uninstall for thelower fixture 119 for changing fixtures quickly and effortlessly whenpress fitting different sized fixtures, for example, on a manufacturingproduction line. This is certainly quicker than bolting and unboltingcomponents. Any type of hose may be used in this embodiment or otherembodiments using hose. Single layer hose may be used, multilayered hosemay be used, and any hose may be used, so long as it protects thesurface of the developer roller 2 from scratching or other damage. Forexample, some of the hose materials that may be used are rubber,urethane, urethane rubber, air hose, water hose, cooling hose,automotive hose, air conditioning hose, compressed air hose, fish-tanktubing, garden hose, hydraulic hose, neoprene rubber, hard rubber, softrubber, closed cell foam, open cell foam, among many other hoses, tubes,rubber pipe, molded rubber or extruded rubber. There is no limit inpossibilities in types of hoses and tubing to use for the quick connectfeature in this and other embodiments. Please note that inventorinvented a quick connect lathe adapter set for quickly installing anduninstalling lathe adapters for quick connect shown in U.S. Pat. Nos.5,309,200 and 5,381,213.

FIGS. 24 and 25 show an upper fixture holder module 92 with an upperfixture 127 attached from the bottom 98 of the upper fixture holdermodule 92. A bolt 109 (not shown) may be used to bolt the upper fixturemodule 92 to the ram 76. The fixture 127 may optionally have a bore 129to attach to the fixture holder 92 with a bolt or other fastener. Thefixture 127 has a bottom 184 to be inserted into the press-fit part. Forexample, this is a male fixture 127 as opposed to the female upperfixture 111. The male fixture 127 may be used to press-fit a componentthat is female such as the contact 25 shown in FIGS. 4 and 5. The bottom184 of the fixture 127 inserts into the contact's 25 first portion 28and abuts against the contact surface 30 of the contact 25 which allowsthe male fixture 127 to press-fit the contact 25. The same is true ofthis fixture for any female object to be press-fit in any industrywhatsoever and is not limited to the imaging industry. When thepress-fit part is steel or other material that is attracted by a magnet,the fixture 127 may be made magnetic so the press-fit part can stay inby magnetism. One way to do this is to make the fixture 127 of steel andto magnetize it although the same may be done by using magnetite ormagnetic steel. The fixture 127 has an upper fixture stem 129 (topportion) which has a top 131 and a bore 132. The fixture has a base 184and a stem joins base region 130 at the base 184's top 128. Although themale fixture 127 is shown as an upper fixture, there could also be alower male fixture designed the same way but upside down and it wouldhave all the same features, and thus it is hereby incorporated in thispatent application by having described the upper fixture 127 to savespace. Similarly, the upper fixture 127 may be installed using a hose onthe inside bore of the fixture holder 92 and/or 94 so the fixture 127may be installed and uninstalled quickly into either fixture holder 92or 94.

FIG. 26 shows an isometric cutaway view of the arbor press. Whenpress-fitting developer rollers are placed in the narrow base opening 80as in FIG. 14, since many developer rollers 2 are very magnetic bydesign, there is a tendency for the outer surface of the developerroller to strongly attract to the base 79 of the arbor press 70 at theinner surface 93 of the base opening region 80. It is this attractionthat can easily score the sensitive surface of the developer roller 2and cause a print defect. For this reason, some soft material 133 isinserted inside the base opening 80 to prevent damage to the developerroller 2. Many soft materials 133 may be used, for example, ester opencell foam, ether open cell foam, any open cell foam, closed cell foam,foam, rubber, foam rubber, cloth, cotton, fabric, wool, polyurethane,polyurethane foam, any open cell material, any closed cell material, anysoft material, any cushiony material. If the poles are known on thedeveloper rollers, like poled magnets may be used in place of the softmaterial 133 to repel the developer roller from touching the baseopening 80. FIG. 27 shows a cutaway top view of the arbor press with thesoft material 136 installed to protect the developer roller 2. Softmaterial 136 may be installed as the figure shows right side softmaterial 135 and left side soft material 134 in the opening 80 of thebase 79 of the arbor press 70. FIG. 28 shows the arbor press 70 with theextender 83 and the installed soft protective material 133, in this caseopen cell ester foam. I like the ester foam best because my daughter'sname is Esther.

FIG. 29 shows a prior art quick connect universal coupler 137, and threedifferent quick connect nipples from the air hose (compressed air)industry. The three quick connect nipples are references 138, 139 and140, each one different. The universal coupler 137 may be used by any ofthe nipples 138, 139 or 140, even though each nipple has a completelydifferent design as seen in FIG. 29. There are many more designs ofcouplers too numerous to mention which are to be incorporated in thisinvention even though they are not all shown.

FIG. 30 shows a typical quick connect coupler 141, different from theone previously shown. The quick connect coupler 141 has a male pipethread 142 which is more suitable to the application of using a coupler141 to replace the upper and lower fixture holders 92 and 94. By using acoupler 141 with a male thread 142, the coupler would install into thethreaded bore 87 in the base 86 of the extender 83. By simply replacingthe lower fixture holder module 94 with a coupler 141, a different quickconnect embodiment may be made. The same is true of the upper fixtureholder module 92. The coupler assembly 141 may also replace the upperfixture holder module 92 in the ram 76 of the arbor press 70 and thecoupler assembly 141 may instead be installed in a hole drilled andtaped in the ram 76. In order to use the couplers 137 or 141 as eitherupper or lower fixture holders, the upper and lower fixtures 111 and 119must have a hole drilled and tapped in them to receive the male threads149 of a nipple 148 as shown in FIG. 31. The nipple 148 has a male pipethread to allow the nipple to screw into a tapped hole in a quickconnect fixture 156 as shown in FIG. 32. Please note that the figuresshow that the nipple 148 has a male thread 149, a hex wrench turnportion 150, a bottom end 151, a bottom bore 152, a top end 153, a topbore 154 and a nipple push lock 155. The coupler 141 has a male pipethread 142, a thread end 143, a quick connect end 144, a hex-wrench turnportion 145, a sliding ring 146 and a bottom bore 147. The quick connectfixture 156 of FIG. 32 may be used either as an upper or lower fixtureand has a first lower bore 157 and a second upper bore 158. The fixture156 can quickly connect and disconnect from an upper or lower fixtureholder 141 coupler (not shown in an arbor press), and a user can acquirea set of fixtures similar to 156, each of a different size and quicklyplug them in and out of coupler fixture holders such as 141 located inan arbor press 70 ram 76 or on the threaded hole 87 of the base 86 of anextender 83 for quick changeover on a production line or any workenvironment.

FIG. 33 shows a cutaway isometric view of a quick connect coupler 137and a quick connect nipple 138. Shown in the figure on the nipple 138 isthe hex wrench turn portion 150, the top end 153, the bore 154 in thetop 153 and the nipple push lock 155. Shown in the figure on the couplerare the precision seal 159 and the knurl 160 for easy gripping. Ofcourse, since the couplers are not used for a compressed air hose, theprecision seal is not necessary. To use an existing coupler and nipplethat is already equipped with unnecessary features relating to apneumatic compressed air line does not hurt the performance of using thequick connect coupler and nipple solely for the quick connect features.FIG. 34 shows a cutaway isometric view of a coupler 162 and a nipple 161from the hydraulic industry, used to quickly connect hydraulic lines.The hydraulic coupler 162 and nipple 161 may also be used similar to thepneumatic coupler 137 and nipple 138 as already described. The hydrauliccoupler 162 has a ball locking mechanism 164. The hydraulic nipple 161has a nipple push lock 163 to secure the nipple 161 into the coupler162.

Since minor changes and modifications varied to fit particular operatingrequirements and environments will be understood by those skilled in theart, the invention is not considered limited to the specific exampleschosen for purposes of illustration. The invention includes all changesand modifications which do not constitute a departure from the truespirit and scope of this invention as claimed in the following claimsand as represented by reasonable equivalents to the claimed elements.Any ideas shown in any embodiments may be incorporated into any otherembodiments. Any prior art disclosed may be incorporated with anyembodiment disclosed.

1. An improved electrical connection device for use in an image formingapparatus comprising of a printer, copy machine or a facsimile machineor a toner cartridge used therein to supply a bias voltage to adeveloper roller whereby a bias voltage contact fits into the developerroller whereby said bias voltage contact has a first portion that fitsinto the developer roller and whereby a second portion is cylindricaland rotates inside an electrobushing; whereby said electrobushing actsas an electrical contact and also as a bearing and has a bore sized toreceive said second portion of said bias voltage contact; wherein afirst end of said electrobushing makes electrical continuity with apower supply of the image forming apparatus; and a second end of saidelectrobushing receives said second portion of said bias voltage contactand thus said electrobushing makes electrical continuity with saidsecond portion of said bias voltage contact; and thus saidelectrobushing not only acts as a bearing but also helps supplyelectricity to the developer roller.
 2. An improved electricalconnection device as in claim 1 whereby said electrobushing has acylindrical portion.
 3. An improved electrical connection device as inclaim 2 whereby said electrobushing has a rim.
 4. An improved electricalconnection device as in claim 3 whereby said electrobushing has a flatring shaped portion formed where said cylindrical portion joins saidrim.
 5. An improved electrical connection device as in claim 3 whereinsaid rim has a first flat surface that makes rotational electricalcontact with a second flat surface on said bias voltage contactpositioned in distance where said first portion and said second portionjoin but perpendicular to central axis of said first portion and atleast the diameter of said first portion.
 6. An improved electricalconnection device as in claim 1 whereby said electrobushing is made ofmetal.
 7. An improved electrical connection device as in claim 1 wherebysaid electrobushing is made of conductive plastic.
 8. An improved imageforming apparatus as in claim 1 wherein said first end of saidelectrobushing makes electrical contact with a contact ring located onsaid endcap.
 9. An improved electrical connection device as in claim 1wherein said first portion of said bias voltage contact has both alarger diameter portion and a smaller diameter portion for making abetter press-fit.
 10. An improved toner cartridge used in an imageforming apparatus comprising of a dry toner style printer, copy machineor facsimile machine; whereby said toner cartridge includes of a lonerhopper and a waste toner hopper; whereby said waste toner hopperincludes of a photoreceptor, a cleaning blade, a charging device forelectrostatically charging said photoreceptor and a container so receivewaste toner; whereby said toner hopper includes of a storage tank, anendcap and a developer roller, whereby a bias voltage contact fits intosaid developer roller; whereby said bias voltage contact has a firstportion that fits inside said developer roller and has electricalcontinuity with an inner wall of said developer roller; whereby a secondportion of said bias voltage contact has a region that is cylindrical inshape; and whereby said cylindrical region of said second portion ofsaid bias voltage contact is of a smaller diameter than said firstportion and rotates in an electrobushing; whereby a first end of saidelectrobushing has a bore to receive said cylindrical portion of saidsecond portion of said bias voltage contact in such a way such that saidelectrobushing acts as a rotational bearing of said cylindrical regionof said second portion of said bias voltage contact; and saidelectrobushing also has electrical continuity with said bias voltagecontact; and a second end of said electrobushing makes electricalcontinuity with a power supply of the image forming apparatus; and thusthe power supply of the image forming apparatus supplies a bias voltagewhich electrically connects to said electrobushing which electricallyconnects to said bias voltage contact which electrically connects tosaid inner wall of said developer roller; whereby said developer rollerthereby receives said bias voltage; and thus with said bias voltage saiddeveloper roller manipulates a toner on an outer surface of saiddeveloper roller whereby said toner is a powder; and thus said developerroller is capable of supplying said toner to said photoreceptor; andthus with said bias voltage said developer roller manipulates said tonersupplied to said photoreceptor; so as to supply the correct amount ofsaid toner to said photoreceptor; and so that said developer roller willreceive back some of the unused said toner that said photoreceptor doesnot use; whereby said toner transported from said developer roller tosaid photoreceptor is manipulated with said bias voltage; and alsounused said toner transported from said photoreceptor and returned tosaid developer roller is also manipulated by said bias voltage.
 11. Animproved toner cartridge as in claim 10 whereby said electrobushing hasa cylindrical portion.
 12. An improved toner cartridge as in claim 11whereby said electrobushing has a rim.
 13. An improved toner cartridgeas in claim 12 whereby said electrobushing has a flat ring shapedportion formed where said cylindrical portion joins said rim.
 14. Animproved electrical connection device as in claim 12 wherein said rimhas a first flat surface that makes rotational electrical contact with asecond flat surface on said bias voltage contact positioned in distancewhere said first portion and said second portion join but perpendicularto said first portion and at least the diameter of said first portion.15. An improved toner cartridge as in claim 10 whereby saidelectrobushing is made of metal.
 16. An improved toner cartridge as inclaim 10 whereby said electrobushing is made of conductive plastic. 17.An improved image forming apparatus as in claim 10 wherein said secondend of said electrobushing makes electrical contact with a contact ringlocated on said endcap.
 18. An improved image forming apparatuscomprising of a dry toner style printer, copy machine or facsimilemachine; whereby said improved image forming apparatus makes an image onmedia; where media may be paper, overhead slide media, microfilm,plastic, labels, cardboard, disk labels, CDROM labels or any dry tonerprintable media used with a xerographic imaging device; whereby saidimproved image forming apparatus contains a toner storage container, awaste toner hopper, a photoreceptor, a cleaning blade, a fuser section,a photoreceptor charging device and a transfer section; whereby saidtoner storage container has a storage lank, an endcap and a developerroller; whereby a bias voltage contact fits in one end of said developerroller; whereby said bias voltage contact has a first portion that fitsinside said developer roller and has electrical continuity with an innerwall of said developer roller; whereby a second portion of said biasvoltage contact has a portion that is cylindrical in shape; and wherebysaid cylindrical portion of said second portion of said bias voltagecontact is of a smaller diameter than said first portion and rotates inan electrobushing; whereby said electrobushing has a bore to receivesaid cylindrical portion of said second portion of said bias voltagecontact at a first end in such a way where said electrobushing acts as arotational bearing of said cylindrical portion of said second portion ofsaid bias voltage contact; and said electrobushing also has electricalcontinuity with said bias voltage contact; and a second end of saidelectrobushing makes electrical contact directly or indirectly with apower supply of said improved image forming apparatus; and thus saidpower supply of said improved image forming apparatus supplies a biasvoltage which electrically connects to said electrobushing whichelectrically connects to said bias voltage contact which electricallyconnects to said inner wall of said developer roller; whereby saiddeveloper roller thereby receives said bias voltage: and thus with saidbias voltage said developer roller manipulates a toner on outer surfaceof said developer roller whereby said toner is a powder; and thus saiddeveloper roller is capable of supplying said toner to saidphotoreceptor; and thus with said bias voltage said developer rollermanipulates said toner supplied to said photoreceptor; so as to supplythe correct amount of said toner to said photoreceptor; and so that saiddeveloper roller will receive some of the unused said toner that saidphotoreceptor does not use; whereby said toner transported from saiddeveloper roller to said photoreceptor is manipulated with said biasvoltage; and also said toner transported from said photoreceptor andreturned to said developer roller is also manipulated by said biasvoltage.
 19. An improved image forming apparatus as in claim 18 wherebysaid electrobushing has a cylindrical portion.
 20. An improved imageforming apparatus as in claim 19 whereby said electrobushing has a rim.21. An improved image forming apparatus as in claim 20 whereby saidelectrobushing has a flat ring shaped portion formed where saidcylindrical portion joins said rim.
 22. An improved electricalconnection device as in claim 20 wherein said rim has a first flatsurface that makes rotational electrical contact with a second flatsurface on said bias voltage contact positioned in distance where saidfirst portion and said second portion join but perpendicular to saidfirst portion and at least the diameter of said first portion.
 23. Animproved image forming apparatus as in claim 18 whereby saidelectrobushing is made of metal.
 24. An improved image forming apparatusas in claim 18 whereby said electrobushing is made of conductiveplastic.
 25. An improved image forming apparatus as in claim 18 whereinsaid second end of said electrobushing makes electrical contact with acontact ring located on said endcap.
 26. A method of making an improvedimage forming apparatus comprising of a dry toner style printer, copymachine or facsimile machine; whereby the improved image formingapparatus makes an image on media; where media may be paper, overheadslide media, microfilm, plastic, labels, cardboard, disk labels, CDROMlabels or any dry toner printable media used with a xerographic imagingdevice; whereby said method involves manufacturing an improved imageforming apparatus which has a toner storage container, a waste lonerhopper, a photoreceptor, a cleaning blade, a fuser section, aphotoreceptor charging device and a transfer section; whereby the tonerstorage container has a storage tank, an endcap and a developer roller;whereby said method involves a step of placing a bias voltage contact inone end of the developer roller; whereby the bias voltage contact has afirst portion that fits inside the developer roller and makes electricalcontact with an inner wall of the developer roller; whereby a secondportion of the bias voltage contact has a portion that is cylindrical inshape is of a smaller diameter than the first portion; and whereby saidmethod involves a step of positioning the cylindrical portion of thesecond portion of the bias voltage contact in an electrobushing wherethe bias voltage contact can rotate; whereby the electrobushing has abore to receive the cylindrical portion of the second portion of thebias voltage contact at a first end in such a way that electrobushingacts as a rotational bearing of the cylindrical portion of the secondportion of the bias voltage contact; and the electrobushing also makeselectrical contact with the bias voltage contact; and a second end theelectrobushing makes electrical contact directly or indirectly with apower supply of the improved image forming apparatus; and thus the powersupply of the improved image forming apparatus supplies a bias voltagewhich electrically connects to the electrobushing which electricallyconnects to the bias voltage contact which electrically connects to theinner wall of the developer roller; whereby the developer roller therebyreceives the bias voltage; and thus with the bias voltage the developerroller manipulates a powdered toner on an outer surface of the developerroller; and thus the developer roller is capable of supplying the tonerto the photoreceptor; and thus with the bias voltage the developerroller manipulates the toner supplied to the photoreceptor; so as tosupply the correct amount of the toner to the photoreceptor; and so thatthe developer roller will take back some of the unused the toner thatthe photoreceptor does not use; whereby the toner transported from thedeveloper roller to the photoreceptor is manipulated with the biasvoltage; and also the toner transported from the photoreceptor andreturned to the developer roller is also manipulated by the biasvoltage.
 27. A method as in claim 26 whereby the electrobushing bas acylindrical portion.
 28. A method as in claim 26 whereby theelectrobushing has a rim.
 29. A method as in claim 28 whereby theelectrobushing has a flat ring shaped portion formed where thecylindrical portion joins the rim.
 30. A method as in claim 28 whereinthe rim of the electrobushing has a first flat surface that makesrotational electrical contact with a second flat surface on the biasvoltage contact positioned in distance where the first portion and thesecond portion join but perpendicular to the cental axis of the firstportion and at least the diameter of the first portion, a step involvingpositioning the rim of the electrobushing to make electrical contactwith the second flat surface of the bias voltage contact.
 31. A methodas in claim 26 wherein a step in the process is included where thesecond end of the electrobushing makes electrical contact with a contactring located on the endcap; and whereby a step involves positioning theelectrobushing so that it electrically contacts the contact ring.
 32. Animproved electrical connection device for use in an image formingapparatus comprising of a printer, copy machine or a facsimile machineor a toner cartridge used therein to supply a bias voltage to adeveloper roller whereby a bias voltage contact fits into the developerroller; and whereby said bias voltage contact has a first portion thatfits into the developer roller; and whereby said bias voltage contacthas a second portion which is cylindrical; and wherein the developerroller has a counterbore and therefore has a larger diameter bore regionand a smaller diameter bore region; and said first portion of said biasvoltage contact has a larger diameter portion and a smaller diameterportion; and said larger diameter portion of said first portion of saidbias voltage contact fits into the larger diameter bore region whilesaid smaller diameter portion of said first portion of said bias voltagecontact fits into the smaller diameter bore region.
 33. An improvedelectrical connection device as in claim 32 wherein said first portionof said bias voltage contact press-fits into the developer roller. 34.An improved electrical connection device as in claim 32 wherein a springmakes electrical contact between said second portion of said biasvoltage contact and a power supply of the image forming apparatus. 35.An improved electrical connection device as in claim 32 wherein a springmakes electrical contact between said second portion of said biasvoltage contact and a contact ring in an endcap of the toner cartridge.36. An improved toner cartridge used in an image forming apparatuscomprising of a dry toner style printer, copy machine or facsimilemachine; whereby said toner cartridge comprises of a toner hopper and awaste toner hopper; and whereby said waste loner hopper comprises of aphotoreceptor, a cleaning blade, a charging device for electrostaticallycharging said photoreceptor and a container to receive waste toner; andwhereby said toner hopper comprises of a storage tank, an endcap and adeveloper roller; and whereby a bias voltage contact fits into saiddeveloper roller; and whereby a first portion of said bias voltagecontact has a region that is cylindrical in shape that fits inside saiddeveloper roller and has electrical continuity with an inner wall ofsaid developer roller; and wherein said developer roller has acounterbore and therefore has a larger diameter bore region and asmaller diameter bore region; and said first portion of said biasvoltage contact has a larger diameter portion and a smaller diameterportion; and said larger diameter portion of said first portion of saidbias voltage contact fits into said larger diameter bore region whilesaid smaller diameter portion of said first portion of said bias voltagecontact fits into said smaller diameter bore region for a better fit andbetter electrical connection with inner wall of said developer roller;and wherein said bias voltage contact has a second portion.
 37. Animproved toner cartridge as in claim 36 wherein said first portion ofsaid bias voltage contact press-fits into said developer roller.
 38. Animproved toner cartridge as in claim 36 wherein a spring makeselectrical contact between said second portion of said bias voltagecontact and a power supply of the image forming apparatus.
 39. Animproved toner cartridge as in claim 36 wherein a spring makeselectrical contact between said second portion of said bias voltagecontact and a contact ring in said endcap of said toner cartridge. 40.An improved image forming apparatus comprising of a dry toner styleprinter, copy machine or facsimile machine; whereby said improved imageforming apparatus makes an image on media; where media may be paper,overhead slide media, microfilm, plastic, labels, cardboard, disklabels, CDROM labels or any dry toner printable media used with axerographic imaging device; whereby said improved image formingapparatus contains a toner storage container, a waste toner hopper, aphotoreceptor, a cleaning blade, a fuser section, a photoreceptorcharging device and a transfer section; whereby said toner storagecontainer has a storage tank, an endcap and a developer roller; wherebya bias voltage contact fits in one end of said developer roller; wherebysaid bias voltage contact bas a first portion that fits inside saiddeveloper roller and has electrical continuity with an inner wall ofsaid developer roller; whereby a second portion of said bias voltagecontact has a portion that is cylindrical in shape and is of a smallerdiameter than said first portion; and wherein said developer roller hasa counterbore and therefore has a larger diameter bore region and asmaller diameter bore region; and said first portion of said biasvoltage contact has a larger diameter portion and a smaller diameterportion; and said larger diameter portion of said first portion of saidbias voltage contact fits into said larger diameter bore region whilesaid smaller diameter portion of said first portion of said bias voltagecontact fits into said smaller diameter bore region for a better fit andbetter electrical connection.
 41. An improved image forming apparatus asin claim 40 wherein said first portion of said bias voltage contactpress-fits into said developer roller.
 42. An improved image formingapparatus as in claim 40 wherein a spring makes electrical contactbetween said second portion of said bias voltage contact and a powersupply of said improved image forming apparatus.
 43. An improved imageforming apparatus as in claim 40 wherein a spring makes electricalcontact between said second portion of said bias voltage contact and acontact ring in said endcap.
 44. A method of making an improved imageforming apparatus comprising of a dry toner style printer, copy machineor facsimile machine; and whereby the improved image forming apparatusmakes an image on media; and whereby media may be paper, overhead slidemedia, microfilm, plastic, labels, cardboard, disk labels, CDROM labelsor any dry toner printable media used with a xerographic imaging device;and whereby said method involves manufacturing an improved image formingapparatus which has a toner storage container, a waste toner hopper, aphotoreceptor, a cleaning blade, a fuser section, a photoreceptorcharging device and a transfer section; whereby the toner storagecontainer has a storage tank, an endcap and a developer roller; wherebythe developer roller has a developer roller sleeve; and whereby saidmethod involves a step of placing a bias voltage contact in one end ofthe developer roller sleeve; whereby the bias voltage contact has afirst portion that fits inside the developer roller sleeve and haselectrical continuity with an inner wall of the developer roller sleeve;whereby a second portion of the bias voltage contact has a portion thatis cylindrical in shape and is of a smaller diameter than the firstportion; and whereby said method involves another step of making acounterbore in the developer roller sleeve whereby the developer rollersleeve has a larger diameter bore region and a smaller diameter boreregion; and a first portion of the bias voltage contact has a largerdiameter portion and a smaller diameter portion; and the larger diameterportion of the first portion of the bias voltage contact fits into thelarger diameter bore region while the smaller diameter portion of thefirst portion of the bias voltage contact fits into the smaller diameterbore region for a better fit and better electrical connection.
 45. Amethod as in claim 44 wherein said method involves a step wherein thefirst portion of the bias voltage contact press-fits into the developerroller.
 46. A method as in claim 44 wherein said method involves a stepwherein a spring electrically connects the second portion of a biasvoltage contact to the power supply of the improved image formingapparatus.
 47. A method as in claim 44 wherein said method involves astep wherein a spring electrically connects the second portion of thebias voltage contact to a contact ring in the end cap of a tonercartridge.